Injection molding flow control apparatus and method

ABSTRACT

Injection molding apparatuses and methods wherein a valve pin is controllably driven upstream and downstream along an axis between a first closed position where the tip end of the valve pin obstructs the gate to prevent the injection fluid from flowing into the cavity, a full open position and one or more intermediate positions, wherein the valve pin is drivable to be disposed or held in a selected intermediate position for a selected period of time during the course of an injection cycle where the tip end of the valve pin restricts flow of injection fluid through the gate to the mold cavity.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of and claims the benefit ofpriority to U.S. application Ser. No. 16/054,386 filed Aug. 3, 2018,which is a continuation of and claims the benefit of priority to U.S.application Ser. No. 15/432,175 filed Feb. 14, 2017, which is acontinuation of and claims the benefit of priority to U.S. applicationSer. No. 14/930,692 filed Nov. 3, 2015, which is a continuation of andclaims the benefit of priority to U.S. application Ser. No. 13/569,464filed Aug. 8, 2012. The disclosures of these applications areincorporated by reference in their entirety as if fully set forthherein.

BACKGROUND

Injection molding systems have been developed having flow controlmechanisms (e.g., a controller) that control the movement and/or rate ofmovement of a valve pin over the course of an injection cycle to causethe pin to move to one or select positions and/or to control the rate ofmovement of the pin over the course of the injection cycle. In oneembodiment, the pin movement is controlled in order to raise or lowerthe rate of flow of fluid material to correspond to a predeterminedprofile of fluid flow rates for the injection cycle. A sensor istypically provided that senses a condition of the fluid material or ofthe apparatus (such as pin position) and sends a signal indicative ofthe sensed condition to a program contained in a controller that usesthe signal as a variable input to control movement of the valve pin inaccordance with the predetermined profile.

SUMMARY OF THE INVENTION

In accordance with one embodiment of the invention, a flow controlsystem is provided for implementing an injection molding process inwhich one or more nozzles, during an injection cycle, feed fluidmaterial(s) into a cavity of a mold, each nozzle having an associatedvalve pin, driven by an associated actuator, for opening and closing arespective gate into the cavity, and a position sensor is associatedwith each valve pin for monitoring a plurality of actual pin positionswith respect to the gate and generating a sensor output signalindicative of the plurality of actual pin positions as the valve pinmoves between gate closed and gate open positions, the flow controlsystem comprising:

a junction box coupled to a recipe storage on the mold and providing awireless communication interface for transmitting and receiving wirelesscommunications with each of:

-   -   a controller that controls movement of each valve pin over the        course of the injection cycle in accordance with a set of        process parameters, the controller being in wireless        communication with the junction box;    -   a mobile user interface, in wireless communication with the        junction box, configured to receive input from a human operator        in the form of process parameters and commands relating to the        injection molding process for wireless transmission to at least        one of the junction box and the controller;

the flow control system being configured to receive and process thesensor output signal from an associated position sensor to determine,from the plurality of actual pin positions, one or more actual processparameters; and

a user display being configured to receive and display the plurality ofactual pin positions and/or the one or more actual process parameters bywhich a human operator can track the molding process in real time duringthe injection cycle.

In one embodiment, the user display is provided on the mobile userinterface.

In one embodiment, the wireless communication interface comprises aradio frequency (RF) transceiver configured for bi-directionalcommunication with the mobile user interface. The RF transceiver mayconsist of one or more of a Wi-Fi antenna, a Bluetooth antenna, and anNFC (Near Field Communication) antenna.

In one embodiment, the flow control system is configured to use the RFtransceiver to transmit, to the mobile user interface, data indicativeof the plurality of actual pin positions and/or the one or more actualprocess parameters.

In one embodiment, the flow control system is configured to use the RFtransceiver to transmit, to the mobile user interface, data comprisingone or more of: pin position status; pin opening and/or pin closingtimes; pin opening and/or pin closing velocities; and continuous actualpin position data for a graphical display of the plurality of actual pinpositions versus time.

In one embodiment,

one or more of the junction box and the controller are configured toprocess the sensor output signal to generate a control signal to controlthe pin position; and

the mobile user interface is configured to receive user input foradjusting the control signal to control the pin position,

In one embodiment, the mobile user interface includes operator commandsfor one or more modes of operation including calibration, continuousmonitoring of the actual pin position, and discrete determination of theactual pin position as opened or closed.

In one embodiment, calibration is triggered by input to the mobile userinterface from the human operator.

In one embodiment, in response to the operator input, the mobile userinterface is configured to generate a calibration command and transmitthe calibration command to one or more of the junction box and thecontroller.

In one embodiment, one or more of the junction box and the controllerare configured to calibrate the position sensor associated with eachvalve pin in response to the calibration command being received by oneor more of the junction box and the controller.

In one embodiment, calibration data for each calibrated position sensoris stored locally in a memory of the junction box.

In one embodiment, the mobile user interface comprises a mobiletelephone, smartphone, or tablet.

In one embodiment, the display comprises a display for viewing one ormore of: a status indicator of the actual pin position; a graph of theactual pin position versus time; and the actual pin opening time and pinopening velocity.

In one embodiment, the position sensor comprises a Hall Effect sensor ora Hall Effect circuit including a Hall Effect sensor and one or more ofa power regulator, signal amplifier, current converter, and signaldriver.

In one embodiment,

the Hall Effect sensor generates a voltage output signal;

the voltage output signal is amplified and converted to a current outputsignal by the Hall Effect circuit; and

the current output signal is transmitted as the sensor output signalfrom an output port of the Hall Effect circuit to an input port of thejunction box or the controller.

In accordance with one embodiment of the invention, a method is providedof monitoring valve pin positioning in an injection molding systemhaving a cavity with one or more gates and one or more actuator-drivenvalve pins each associated with a respective gate for opening andclosing the respective gate, the method comprising, for each of therespective actuator-driven valve pins:

controlling, via a flow control system that implements a set of processparameters for controlling a molding process in the cavity, an actuatorthat drives an associated valve pin with respect an associated gate ofthe cavity along a travel path including a plurality of actual pinpositions between gate open and gate closed positions;

detecting, via a position sensor that monitors movement of an associatedvalve pin while the valve pin moves along the travel path between thegate closed position, closing the associated gate to the cavity, to thegate open position, allowing fluid material to flow through the gate andinto the cavity, and transmitting as a position sensor output signal tothe flow control system a detected actual movement of the valve pinalong the travel path upon opening of the gate indicative of an actualpin opening velocity and an actual pin opening time;

receiving the position sensor output signal and generating display dataindicative of actual process parameters including the actual pin openingtime and the actual pin opening velocity; and

displaying, via a user display, the display data enabling a humanoperator to track the actual process parameters in real time during theinjection cycle including the actual pin opening time and the actual pinopening velocity;

wherein the flow control system includes a junction box coupled to arecipe storage on the mold and providing a wireless communicationinterface for transmitting and receiving wireless communications witheach of the controller and a mobile user interface, and the methodfurther comprising:

receiving, by the mobile user interface, input from a human operator inthe form of process parameters or commands relating to the injectionmolding process for wireless transmission to at least one of thejunction box and the controller.

In one embodiment of the method, the user display is provided on themobile user interface.

In one embodiment, the method comprises using a radio frequency (RF)transceiver as the wireless communication interface to performbi-directional communication with the mobile user interface.

In one embodiment of the method, the RF transceiver comprises one ormore of a Wi-Fi antenna, a Bluetooth antenna, and an NFC (Near FieldCommunication) antenna.

In one embodiment, the displaying step includes generating as thedisplay data continuous actual pin position data for a graphical displayof the plurality of actual pin positions versus time and transmittingthe display data to the mobile user interface via the RF transceiver.

In one embodiment, the controlling step includes:

using the position sensor output signal as a variable input to controlsubsequent movement of the valve pin in accordance with the actualprocess parameters; and

receiving, at the mobile user interface, user input for adjusting thecontrol signal to control the pin position.

In one embodiment, the method is adapted for use in calibration of theinjection molding system, wherein calibration is triggered by an inputto the mobile user interface from the human operator.

In one embodiment of the method, the mobile user interface is configuredto generate a calibration command and transmit the calibration commandto one or more of the junction box and the controller via the RFtransceiver.

In one embodiment, one or more of the junction box and the controllercalibrate the position sensors associated with each valve pin inresponse to the calibration command being received by the RFtransceiver.

In one embodiment, the method further comprises storing calibration datafor each calibrated position sensor locally in a memory of the junctionbox.

In one embodiment, the displaying step comprises displaying a statusindicator of the actual pin position for one or more of the pins of theinjection molding system.

In one embodiment, the displaying step comprises displaying datacomprising one or more of: pin position status; pin opening and/or pinclosing time; pin opening and/or pin closing velocities; and continuousactual pin position data for a graphical display of the plurality ofactual pin positions versus time.

In one embodiment of the method, the position sensor comprises one ormore Hall Effect sensors for an associated valve pin.

In accordance with one embodiment of the invention, a flow controlapplication is provided for monitoring flow control during an injectionmolding process in which one or more nozzles, during an injection cycle,feed fluid material(s) into a cavity of a mold, each nozzle having anassociated valve pin, driven by an associated actuator, for opening andclosing a respective gate into the cavity, and a controller controlsmovement of the valve pins over the course of the injection cycle inaccordance with a set of process parameters, the flow controlapplication providing an interactive screen and a user display on amobile user interface and a wireless communication channel with at leastone of a junction box and a controller for monitoring flow controlduring the injection cycle, wherein the interactive screen enables anoperator to input process parameters or commands, via the wirelesscommunication channel, for one or more of the controller and thejunction box for performing a method including steps of:

monitoring, via a position sensor associated with each valve pin, aplurality of actual pin positions with respect to the gate andgenerating a sensor output signal indicative of the plurality of actualpin positions as the valve pin moves between gate closed and gate openpositions;

processing, via the controller, the sensor output signal from theassociated position sensor to determine, from the plurality of actualpin positions, one or more actual process parameters; and

displaying, on the user display, the plurality of actual pin positionsand/or the one or more actual process parameters by which a humanoperator can track the molding process in real time during the injectioncycle.

In one embodiment of the flow control application, the wirelesscommunication channel comprises a radio frequency (RF) transceiver onthe junction box configured for bi-directional communication with themobile user interface.

In one embodiment of the flow control application, the RF transceivercomprises one or more of a Wi-Fi antenna, a Bluetooth antenna, and anNFC (Near Field Communication) antenna.

In one embodiment of the flow control application, the junction box isfurther configured to use the RF transceiver to transmit, to the mobileuser interface, data indicative of the plurality of actual pin positionsand the one or more actual process parameters.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and further advantages of the invention may be betterunderstood by referring to the following description in conjunction withthe accompanying drawings in which:

FIG. 1 is a schematic of one embodiment of the invention utilizingmicrocontrollers (MCUs) for monitoring and/or controlling an injectionmolding process, the system including a recipe MCU located at the moldand a flow control MCU preferably remote from (optionally local to) themold, and various human operator interfaces remote from the mold formonitoring and/or providing input to the MCUs with regard to theinjection molding process;

FIG. 2 is a flow chart illustrating one method embodiment of theinvention;

FIG. 3 is a flow chart illustrating another method embodiment of theinvention;

FIG. 4 is a flow chart illustrating another method embodiment of theinvention;

FIG. 5 is a flow chart illustrating another method embodiment of theinvention;

FIG. 6 is a schematic of one embodiment of an injection moldingapparatus utilizing the invention during an injection molding cycle,namely a recipe (of process parameters) stored on a recipe storagesystem mounted in a mold is transmitted to and executed by a controller,the molding apparatus including a pair of sequential gates with a firstgate entering a center portion of a mold cavity having been opened andnow closed such that a first shot of fluid material has entered thecavity and traveled past the positions of a pair of second sequentialgates (one at each end of the mold cavity), each second gate being openwith its valve pin having traveled along an upstream restricted flowpath RP allowing a second sequential shot of fluid material to flow intoand merge with the first shot of material within the cavity;

FIGS. 6A-6E are schematic cross-sectional close-up views of the centerand one of the lateral gates of the FIG. 6 apparatus showing variousstages of the progress of injection;

FIG. 7 is a schematic of one embodiment of a hydraulically actuatedvalve pin in which at least one port of an actuator is connected to aflow restrictor so as to restrict the flow of hydraulic drive fluid andslow the opening of the valve pin by a selected lessening of pin openingvelocity by use of a controller interconnected to the flow restrictor,the controller enabling the user to select a percentage of predeterminedfull open position velocity that the hydraulic drive supply to theactuator normally operates at full open velocity drive fluid pressure;

FIGS. 7A, 7B are schematic cross-sectional views of the hydraulic valvesand restrictors used in the system of FIG. 6;

FIGS. 8A, 8B show various embodiments of piston sensors that can be usedin a variety of implementations of the invention, the sensors shown inthese figures being mounted so as to measure the position of the pistoncomponent of the actuator which is indicative of the position of thevalve pin relative to the gate;

FIGS. 8C, 8D show embodiments using limit switches that detect andsignal specific positions of the actuator that can be used to determinevelocity, position and switchover to higher openness of valve restrictorand/or upstream velocity of travel of the actuator and valve pin;

FIGS. 9A-9D are a series of graphs representing actual pressure (versustarget pressure) measured in four injection nozzles coupled to amanifold, such as in the apparatus of FIG. 6; and

FIG. 10 shows an interactive screen display of a user interface, such asthat shown in FIG. 1, which screen is used to display, create, edit andstore target profiles.

DETAILED DESCRIPTION

Various embodiments of the present invention are now described withreference to the drawings. In the following description, for purposes ofexplanation, numerous specific details are set forth in order to providea thorough understanding of one or more implementations of the presentinvention. It will be evident, however, that the present invention maybe practiced without these specific details. In other instances,well-known structures and devices are shown in block diagram form inorder to facilitate describing the present invention.

As used in this application with regard to various monitoring andcontrol systems, the terms “component” and “system” are intended torefer to a computer-related entity, either hardware, a combination ofhardware and software, software, or software in execution. For example,a component may be, but is not limited to being, a process running on aprocessor, a processor, an object, an executable, a thread of execution,a program, and/or a computer. By way of illustration, both anapplication running on a server and the server can be a component. Oneor more components may reside within a process and/or thread ofexecution and a component may be localized on one computer and/ordistributed between two or more computers.

The present invention may also be illustrated as a flow chart of aprocess of the invention. While, for the purposes of simplicity ofexplanation, the one or more methodologies shown in the form of a flowchart are described as a series of acts, it is to be understood andappreciated that the present invention is not limited by the order ofacts, as some acts may, in accordance with the present invention, occurin a different order and/or concurrent with other acts from that shownand described herein. For example, those skilled in the art willunderstand and appreciate that a methodology could alternatively berepresented as a series of interrelated states or events, such as in astate diagram. Moreover, not all illustrated acts may be required toimplement a methodology in accordance with the present invention.

In various embodiments of the invention disclosed herein, the term“data” is used. Data means any sequence of symbols (typically denoted“0” and “1”) that can be input into a computer, stored and processedthere, or transmitted to another computer. As used herein, data includesmetadata, a description of other data. Data written to storage may bedata elements of the same size, or data elements of variable sizes. Someexamples of data include information, program code, program state,program data, other data, and the like.

As used herein, computer storage media includes both volatile andnon-volatile, removable and non-removable media for storage ofinformation such as computer-readable instructions, data structures,program modules, or other data. Computer storage media includes RAM,ROM, EEPROM, FLASH memory or other memory technology, CD-ROM, digitalversatile disc (DVDs) or other optical disk storage, magnetic cassettes,magnetic tape, magnetic disk storage or other magnetic storage devices,or any other medium which can be used to store desired information andwhich can be accessed by the computer.

The methods described below may be implemented in a suitable computingand storage environment, e.g., in the context of computer-executableinstructions that may run on one or more processors, microcontrollers orother computers. In a distributed computing environment (for example)certain tasks are performed by remote processing devices that are linkedthrough a communications network and program modules may be located inboth local and remote memory storage devices. The communications networkmay include a global area network, e.g., the Internet, a local areanetwork, a wide area network or other computer network. It will beappreciated that the network connections described herein are exemplaryand other means of establishing communications between the computers maybe used.

A computer may include one or more processors and memory, e.g., aprocessing unit, a system memory, and system bus, wherein the system buscouples the system components including, but not limited to, the systemmemory and the processing unit. A computer may further include diskdrives and interfaces to external components. A variety ofcomputer-readable media can be accessed by the computer and includesboth volatile and nonvolatile media, removable and non-removable media.A computer may include various user interface devices including adisplay screen, touch screen, keyboard or mouse. In some embodiments, acomputer can be provided as a desktop computer, a laptop computer, aportable computing device, a mobile phone, a tablet, etc.

A microcontroller (MCU) is used in the present invention to control someor all of the functions of an electronic device or system. An MCU is asmall self-contained computer chip, essentially comprising a smallcomputer on a single integrated circuit and including a microprocessor,memory, and I/O on a single chip. The chip may be programmed for selectfunctions, the program code being stored on Flash, EPROM or othernon-violate memory. An MCU is used in each of a recipe storage system, aflow control system, and a user interface system in the embodimentdescribed below. The MCU may be embedded in a printed circuit board(PCB), e.g., within the main PCB of the controller, a PCB within astorage device (in a junction box) and/or a PCB within an input device(such as a voice input interface). In contrast, PLC's (programmablelogical controllers) are costly and not as effective (too slow and/oroffer limited functionality).

Flow Control Apparatus and Method

FIG. 1 is a schematic diagram of a flow control apparatus and methodaccording to one embodiment of the invention. In the disclosedembodiment, a recipe storage MCU and flow control MCU replace the priorknown controller, and preferably communicate with a new operatorinterface. It is to be understood that the new flow control apparatusand method can be used with various injection molding machines andmolding processes known to the skilled person.

In the advanced flow control system 10 of the present embodiment, acontroller 8 includes a flow control microcontroller (MCU) 9, alsoreferred to as the main MCU. The main MCU 9 is operative to communicate(over wired or wireless media 29) with one or more types of userinterfaces 21 including for example a voice activated interface 23, amobile (Wi-Fi) interface 25, and a wired interface 27. In someembodiments, one or more of the types of user interfaces 21 can beprovided on a computing device that is separate from controller 8 andmain MCU 9. For example, mobile (Wi-Fi) interface 25 could be providedas an application running on a mobile phone of a user (human operator)31. Although reference is made to mobile interface 25 being a Wi-Fiinterface, it is appreciated that various other wireless and radiofrequency communication protocols can be utilized to implement mobileinterface 25, including but not limited to, Wi-Fi, Bluetooth, NFC (NearField Communication), etc. Such a mobile application can allow user 31to use the same mobile phone to connect with, monitor, and/or interactwith multiple mold and injection molding machines 41 (and theirrespective MCUs), which can be particularly advantageous in a factorysetting where multiple mold and injection molding machines are utilized.More generally, user 31 can input to the interface 21 various processparameters, such as inputs to a recipe for controlling various types ofactuators used in the molding process. The inputs will be transmittedfrom the user interface 21 to the main flow control MCU 9. The flowcontrol MCU 9 in turn communicates (over wired or wireless media 51)with a remote recipe storage MCU 16 mounted on a mold 40 of an injectionmolding apparatus 41 (also referred as to an injection molding machine41). Wireless media 51 can be provided by various radio frequency (RF)communication protocols as described above. The mold includes one ormore pins (see FIG. 6) each driven by an actuator 45 for opening andclosing one or more respective mold cavities (see FIG. 6). The actuatormay be any type of known actuator, including electrical, hydraulic, orpneumatic actuators. The actuator drives a pin for opening and closing agate (an opening into the mold cavity), and the movement of the pin maybe monitored by one or more sensors or signals on/from the mold 40 ormachine 41 for determining one or more process parameters such as pinposition, pin velocity, or melt pressure in the cavity or in a fluidchannel upstream of the cavity (e.g., manifold), or temperature in thecavity or in a fluid channel upstream of the cavity, or the mold cyclecount. The recipe, for a respective mold, is stored in the recipestorage MCU 16 which is mounted on the mold 40, and the recipe iselectronically transmitted from the recipe MCU 16 to the main MCU 9,remote from the mold, the latter of which implements computerinstructions for controlling various parameters related to the moldingprocess of the respective mold in accordance with the recipe.

In one example, the flow control (main) MCU 9 will automatically obtainor receive the recipe of process parameters (e.g., set-up information)from the remote recipe MCU 16 which is located on the mold 40 or machine41. This allows for uninterrupted mold changes, namely the mold and itsassociated recipe will be read automatically by the flow control MCU 9,without requiring programming of the flow control MCU. The transmittedrecipe data can be implemented by executing the flow control computerinstructions stored on the flow control MCU 9. For example, the flowcontrol MCU can be used to control the velocity of the pin(s), maintainthe melt pressure at a desired melt pressure profile, and/or sequencethe pin(s) in a mold using various other inputs.

Furthermore, the flow control (main) MCU 9 receives as input(s) from themold 40 and/or machine 41 one or more electronic signals (digital oranalog), over communication channels 51, indicative of the moldingprocess, thus providing a feedback loop for one or more processparameters, e.g., for pressure control based on melt pressure and/orcavity pressure. This feedback can be provided or displayed to anoperator 31, allowing the operator to input changes to the recipe, andthe modified recipe can then be executed by the main MCU (as the newcurrent recipe).

In one embodiment, the recipe storage MCU 16 is mounted on an electricaljunction box 17 (a container for electrical connections) which allowsfor communications between the mold 40 and the flow control MCU 9 inorder to retrieve and store recipes on the mold MCU 16. In someembodiments, the electrical junction box 17 associated with mold MCU 16can further be configured with a communication interface to transmit andreceive data in a wired or wireless fashion (51,29). For example, theelectrical junction box 17 could be configured with one or more of aBluetooth antenna, a Wi-Fi antenna, an NFC (Near Field Communication)antenna, etc., configured to function as a transmitter, receiver, and/ortransceiver of wireless communication interface 17 a. These examples arenot intended to be construed as limiting, as it is appreciated thatvarious other Radio Frequency (RF) antennae and transmission protocolscan be employed without departing from the scope of the presentdisclosure. As shown in FIG. 1, several wireless communication channels29 a couple the wireless interface 17 a of junction box 17 to controller8 (with main MCU 9), to WiFi Mobile User Interface 25 (with WiFi MCU 25a and display 25 b), and to display 71; wireless interface 17 a canimplement a greater of lesser number of wireless channels than shown inFIG. 1. In some embodiments, the communication interface 17 a can beprovided as a separate component, or in a second junction box, andcommunicatively coupled with the electrical junction box 17 in order toprovide wireless transmitting and receiving functionalities. Thecommunication interface 17 a can be provided with a standalone powersource, can draw power from a common feed on mold 40 or machine 41 (i.e.upon which the communication interface is mounted), can draw power froma common feed or source to electrical junction box 17, or somecombination of the above. In addition to communicating the recipe data,the flow control MCU 9 can interact (e.g., via the junction box 17) withvarious optional sensors 50 and signals 53-55 on/from the mold andmachine, such as position sensors, melt pressure sensors, cavitypressure sensors, temperature sensors, screw position and otherinjection molding machine sensor and signals to control the actuation ofeach pin in the mold, or the mold cycle count. FIG. 1 shows varioussignals 51, including recipe signal 52, position signal 53, meltpressure signal 54 and cavity pressure signal 55, being electronicallytransmitted from the mold machine to the remote main MCU 9, e.g., viawired or wireless communication channel(s), although for purposes ofvisual clarity these various signals 51 are not depicted as firstpassing through a junction box 17 and/or mold MCU 16, as has beendescribed above.

As previously described, the user interface 21 enables a user 31 (humanoperator) to observe the tracking of the actual process parameters,versus the target (desired) process parameters, during the injectioncycle in real time, or after the cycle is complete. In one example, theinterface 21 includes an associated display 22 for tracking suchparameters. One type of display is a simple indicator panel (similar topanel 61 shown in communication with the controller 8) that tells theoperator whether the valve pin is open or closed. In this example, thecontrol system can transmit discrete signals indicating whether thevalve pin is closed or opened. In the previous example where the userinterface 21 is a mobile (i.e. Wi-Fi and/or Bluetooth) interface 25,then the associated display 22 can be provided by the touch screendisplay of the user's smartphone, illustrated in FIG. 1 as display 25 b,where the user's smartphone runs a mobile application to provide theaforementioned information and data to the user and to further receiveinputs and commands from the user.

In another example, a display (such as display 71) is provided thatenables continuous position monitoring of the pin, by the user. In thisexample, the control system 8 transmits a signal to drive a displayshowing (e.g., in a graph of position versus time) the position of thevalve pin throughout the injection cycle. In some embodiments, display71 can also be provided by the touch screen display 25 b of the user'ssmartphone, either in combination with the mobile interface 25functionality discussed above or as a standalone functionality. Thegraphical display 71 of pin position versus time can be transmitteddirectly to the smartphone or mobile computing device of human user 21from a Wi-Fi, Bluetooth, or other RF antenna that is provided within orotherwise communicatively coupled with the junction box on mold andinjection machine 41. In some embodiments, display 71 can alternativelyor additionally be provided as a component of indicator panel 61, suchthat the panel 61 provides both a status indication of pin position(e.g. a green light indicates Pin Open; a yellow light indicates Pin inTransition; a red light indicates Pin Closed) and a visual or graphicalindication of pin parameters including pin velocity and pin position vs.time.

The display(s) can be either local or remote with respect to flowcontrol MCU 9, the user interface(s) 21, and/or the mold 40 and machine41. In one example, the pin open/closed indicator panel 61 is mounted onan exterior portion or exterior surface of the injection molding machine41, such that the indicator panel is visible to an individual observingthe injection molding machine 41. In another example, the graphicaldisplay 71 (of pin position versus time) is provided on the userinterface 21, such as on a display screen of a mobile telephone,smartphone, tablet or other computer device. As discussed above, thedata comprising graphical display 71 can be wirelessly transmitted tothe mobile telephone of user 31 via a Wi-Fi, Bluetooth, NFC, or other RFinterface that is associated with or communicatively coupled to theelectrical junction box located on injection molding machine 41 (i.e.the electrical junction box which houses the recipe/mold MCU 16).

In one embodiment, the user interface 21 is a voice activated interface23 and includes a voice interpreter MCU 23 a. Such an interface mayutilize any of various readily available components, such as a voicerecognition chip. As the operator will typically have fairly specificand a limited range of inputs (commands), any of various commerciallyavailable voice recognition software can be used. For example, RSC-364is a single chip that combines the flexibility of a microcontroller withadvanced speech technology, including high-quality speech recognition,speech and music synthesis, speaker verification, and voice record andplayback. A product can use one or all of the RSC-364 features in asingle application. (See, e.g., http://www.sensoryinc.com)

In another embodiment, the operator interface 21 is a mobile interface25, such as a Wi-Fi interface, that can be accessed via a local wirelesshot spot or other wireless communication interface such as the Wi-Fi,Bluetooth, NFC, and other RF antennae and communication interfacesdiscussed above. In some embodiments, the local wireless hot spot can beprovided by one or more of the RF communication interfaces discussedabove. The wireless device can be any of various mobile laptops,tablets, smartphones, or other forms of computers that can runapplications and/or a browser. In one example, a Wi-Fi MCU 25 a receivesinput via the mobile device from the human operator 31 and communicatesparameters/commands to the flow control MCU 9. This would enable theoperator to travel around an injection molding facility or plant, whileusing the same display and mobile computing device to both monitor data(e.g. pin position status, pin opening and closing times/speeds, pinposition vs. time) and input commands to and from multiple injectionmolding machines. Further, assuming the mobile device includes a displayscreen providing process feedback on the existing profile data, theoperator can then generate and transmit changes to the recipe from theuser interface to the mold MCU 16 (either directly or via the main MCU9). The modified recipe can then be stored at the mold MCU 16 as the(new) current recipe.

In some embodiments, the user 31 can additionally utilize his or hermobile computing device (e.g. smartphone or tablet) to perform acalibration process on one or more injection molding machines. Inparticular, the user 31 can use the aforementioned mobile applicationrunning on his mobile computing device to communicate with a giveninjection molding machine 41 via the Wi-Fi, Bluetooth, or other RFcommunication interface that is housed in or coupled to the junction boxon the given injection molding machine. The calibration process can beperformed with respect to the valve pins and position sensors of theinjection molding machine 41 (more detailed discussion of the pins andassociated position sensors is subsequently provided with respect to thevalve pins 1040-1042 and position sensors 1950-195 of FIG. 6).Calibration of pin position sensors (such as Hall Effect sensors) can benecessary because, even though each pin and associated actuator has afixed stroke length, the output (i.e. sensed) voltage from the pinposition sensor can vary slightly. For example, a first sensor mighthave a voltage output range of 1-4 V, while an otherwise identicalsecond sensor might have a voltage output range of 1.5-3 V. Accordingly,a calibration process can be employed to mitigate the effects of thesedeviations in sensor voltage output range. For example, the calibrationprocess for a given sensor can include one or more of correlating afirst output voltage to a fully open pin position, correlating a secondoutput voltage to a fully closed pin position, and calculating a voltagechange per mm of stroke length of the pin (i.e. a V/mm parameter).

In one example, the calibration process begins with the user 31 firstcommanding all pins to the fully closed position. This command can beinput directly into the injection molding machine 41, or can be inputinto the user's mobile computing device and transmitted to the injectionmolding machine 41 over the Bluetooth or other RF communicationinterface at the junction box of the injection molding machine. Once allof the pins are moved to the fully closed position, the user thentransmits a calibration command which begins the actual calibration ofthe pin position sensors on the injection molding machine 41. In someembodiments, if a user attempts to transmit a calibration command beforethe pins are moved to the fully closed position, the user can beprompted or reminded to first move the pins to the fully closed positionand then re-attempt the calibration command. Alternatively oradditionally, the application running on the user's mobile computingdevice can automatically transmit a command to the Bluetooth or RFtransceiver in the junction box of injection molding machine 41 tothereby cause the pins to be moved to the fully closed position beforethe calibration command is subsequently transmitted or initiated.

With the calibration process thus initiated, the pins are then movedfrom the fully closed position to the fully open position. Based on ananalysis of the recorded sensor output voltages over all of the steps ofthe calibration process, the fully closed and fully open sensor outputvoltages can be calculated, along with the V/mm of stroke length, foreach pin. In some embodiments, the user 31 can command the pins to moveto the fully open position, e.g. by inputting the command directly intoinjection molding machine 41, or by inputting the command into themobile application running on the user's mobile computing device suchthat the command is transmitted from the mobile computing device to theinjection molding machine 41 by way of the Bluetooth antenna housed inthe electrical junction box of the injection molding machine. In someembodiments, the calibration steps described above can be automated andtriggered with a single user input (e.g. selection of a button or otherUser Interface element presented by the mobile application running onthe user's smartphone or tablet). After calibration is completed, thegenerated calibration data can be saved to memory in the junction box ofthe injection molding machine 41 (i.e. saved to memory in the recipe MCU16 that is housed within the junction box on the injection moldingmachine 41). In this manner, calibration parameters are stored locallyon the particular injection molding machine to which they pertain, andthe user 31 is able to connect to, monitor and operate multipledifferent injection molding machines, each with different calibrationparameters, while using the same smartphone or tablet each time.

In a further alternative, the user interface 21 is a hardwired interface27 (including e.g., display 22 and pendent MCU 27 a as shown in FIG. 1),such as a desktop computer or computer device with an input keyboard orgraphical user interface. The one or more interfaces 23, 25, 27 can beconnected to the main MCU 9 of controller 8 via wired or wirelesscommunication channels 29.

Flow Control Method

FIG. 2 illustrates one method embodiment 200 of the invention. In step210, the current recipe stored on a recipe storage MCU located on themold, is transmitted to the remote main MCU. In the next step 212, themain MCU executes computer instructions to control the injection moldingprocess in accordance with the current recipe.

Another method embodiment 300 of the invention is illustrated in FIG. 3.In a first step 310, the current recipe is transmitted from the recipestorage MCU located on the mold to the remote main MCU and stored as the(new) current recipe. In a next step 312, the current recipe isdisplayed. In step 314, a human operator (viewing the display)determines whether changes are required to the current recipe. Ifchanges are required, then in step 316 the operator inputs changes tothe current recipe via a remote human operator interface, creating amodified recipe. Next, at step 318, the modified recipe is transmittedto the main MCU and/or recipe storage MCU and stored as the (new)current recipe. Then the method proceeds to step 320, where the main MCUexecutes computer instructions to control the injection molding processin accordance with the current (modified) recipe. Alternatively, if nochanges are required to the current recipe (at step 314), then themethod proceeds immediately to step 320 to execute the computerinstructions in accordance with the current (unmodified) recipe.

FIG. 4 illustrates another method embodiment 400 of the invention. In afirst step 410, the current recipe is transmitted from the recipestorage MCU located on the mold to the remote main MCU. In the next step412, the main MCU executes computer instructions to control theinjection molding process in accordance with the recipe. In the nextstep 414, process feedback is displayed, for example process parametersand/or molded part parameters from which the human operator candetermine whether to make changes to the recipe. In the next step 416,the human operator determines whether changes to the current recipe arerequired. If so, in the next step 418 the operator inputs changes to thecurrent recipe via a remote operator interface creating a modifiedrecipe. In the next step 420, the modified recipe is transmitted to themain MCU and/or the recipe storage MCU. In the next step 422, the mainMCU executes computer instructions to control the injection moldingprocess in accordance with the new current (modified) recipe.Alternatively, if no changes are required (at step 414), then the methodproceeds directly to step 422 to execute the computer instructions inaccordance with the current (unmodified) recipe. In an optional furtherfeedback loop, during or after step 422 the process returns to step 414to display process feedback, wherein the operator can then determine atstep 416 whether to further modify the current (or previously modified)recipe.

FIG. 5 illustrates a further method embodiment 500 of the invention. Ina first step 510, a mold is added or changed having a recipe storage MCUlocated on the mold storing the current recipe. In a next step 512, thecurrent recipe is transmitted from the recipe MCU located on the mold tothe remote main MCU. In a next step 514, the main MCU executes computerinstructions to control the injection molding process in accordance withthe current recipe. Thus, the method illustrated in FIG. 5 would allow amold operator, such as a night-shift operator, to change the moldwithout having to input which recipe to run. The control system (e.g.,of FIG. 1) will automatically identify the mold and run the currentrecipe stored on the mold without any human operator input required.

Injection Molding Apparatus and Method

FIG. 6 shows an injection molding system 1000, including a controller1016 (with a flow control MCU 9 as per FIG. 1) and a recipe storagesystem 1010 (with a recipe storage MCU 16 as per FIG. 1), the latter ofwhich is mounted on a mold 1002 according to one embodiment of theinvention. In this example, three gates feed a mold cavity as specifiedby a recipe of process parameters stored on the mold storage device 1010and transmitted via communication channel 1009 to the main MCU incontroller 1016 for execution.

A central nozzle 1022 is shown in FIG. 6 feeding molten material from aninjection molding machine 1001 through a main inlet 1018 to adistribution channel 1019 of a manifold 1039. The distribution channelcommonly feeds three separate nozzles 1020, 1022, 1024 which allcommonly feed into a common cavity 1030 of a mold 1002 to make onemolded part. A central nozzle 1022 is controlled by actuator 1940 andarranged so as to feed into cavity 1030 at an entrance point or gatethat is disposed at about the center 1032 of the cavity. As shown, apair of lateral nozzles 1020, 1024 feed into the mold cavity 1030 atgate locations that are distal 1034, 1036 to the center gate feedposition 1032.

As shown in FIGS. 6 and 6A-6E, the injection cycle is a cascade processwhere injection is effected in a sequence from the center nozzle 1022first and at a later predetermined time from the lateral nozzles 1020,1024. As shown in FIG. 6A the injection cycle is started by firstopening the pin 1040 of the center nozzle 1022 and allowing the fluidmaterial M (typically polymer or plastic material) to flow up to aposition in the cavity just before 1100 b, the distally disposedentrance into the cavity of the lateral nozzle 1024. Once the fluidmaterial has further travelled just past the entrance to nozzle 1024, atposition 1100 p, the center gate 1032 of the center nozzle 1022 istypically closed by pin 1040 as shown in FIG. 6B. The lateral gates1034, 1036 are then opened by upstream withdrawal of lateral nozzle pins1041, 1042 as shown in FIGS. 6B-6E. The rate of upstream withdrawal ortravel velocity of lateral pins 1041, 1042 is controlled as describedbelow.

In alternative embodiments, the center gate 1032 and associated actuator1940 and valve pin 1040 can remain open at, during and subsequent to thetimes that the lateral gates 1034, 1036 are opened such that fluidmaterial flows into cavity 1030 through both the center gate 1032 andone or both of the lateral gates 1034, 1036 simultaneously.

When the lateral gates 1034, 1036 are opened and fluid material NM isallowed to first enter the mold cavity into the stream M that has beeninjected from center nozzle 1022 past gates 1034, 1036, the two streamsNM and M mix with each other. If the velocity of the fluid material NMis too high, such as often occurs when the flow velocity of injectionfluid material through gates 1034, 1036 is at maximum, a visible line ordefect in the mixing of the two streams M and NM will appear in thefinal cooled molded product at the areas where gates 1034,1036 injectinto the mold cavity. By injecting NM at a reduced flow rate for arelatively short period of time at the beginning when the gates 1034,1036 are first opened and following the time when NM first enters theflow stream M, the appearance of a visible line or defect in the finalmolded product can be reduced or eliminated.

The rate or velocity of upstream withdrawal of lateral pins 1041, 1042starting from the closed position is controlled via controller 1016(FIGS. 6 and 7) which controls the rate and direction of flow ofhydraulic fluid from a drive system 1700 to actuators 1940, 1941, 1942.A “controller,” as used generally herein, refers to electrical andelectronic control apparatuses that comprise a single box or multipleboxes (typically interconnected and communicating with each other) thatcontain(s) all of the separate electronic processing, memory andelectrical signal generating components that are necessary or desirablefor carrying out and constructing the methods, functions and apparatusesdescribed herein. Such electronic and electrical components may includeprograms, microprocessors, computers, PID controllers, voltageregulators, current regulators, circuit boards, motors, batteries andinstructions for controlling any variable element discussed herein suchas length of time, degree of electrical signal output and the like. Forexample a component of a controller, as that term is used herein,includes programs, controllers and the like that perform functions suchas monitoring, alerting and initiating an injection molding cycleincluding a control device that is used as a standalone device forperforming conventional functions such as signaling and instructing anindividual injection valve or a series of interdependent valves to startan injection, namely move an actuator and associated valve pin from agate closed to a gate open position. In addition, although fluid drivenactuators are employed in the disclosed embodiments, actuators poweredby an electric or electronic motor or drive source can alternatively beused as the actuator component. Another embodiment would have thecontroller dynamically control the movement of an actuator andassociated valve pin in order to meet target pressure profiles basedupon (closed loop) feedback received by the controller from the pressuresensor. Yet another embodiment would have the controller trigger theopening and/or closing of an actuator and associated valve pin basedupon a sensed pressure or temperature condition within the cavity.

As shown in FIGS. 7A-7B, a supply of hydraulic fluid 1014 is fed firstthrough a directional control valve 1750 mechanism that switches thehydraulic fluid flow to the actuator cylinders in either of twodirections: fluid out to withdraw the pin upstream, FIG. 7A, and fluidin to drive the pin downstream, FIG. 7B. At the beginning of aninjection cycle the gate of a lateral valve 1034, 1036 is closed and thehydraulic system is in the directional configuration of FIG. 7B. When acycle is started, the directional configuration of the directional valve1750 of the hydraulic system 1700 is switched by controller 1016 to theconfiguration of FIG. 7A. The hydraulic system includes a flowrestriction valve 1600 that can vary the rate of flow of hydraulic fluidto the actuator 1941 under the control of the controller 1016 to varythe rate of travel, upstream or downstream of the piston of the actuator1941 which in turn controls the direction and rate of travel of pin1041. Although not shown in FIGS. 7A, 7B, the hydraulic system 1700controls the direction and rate of travel of the pistons of actuators1950 and 1952 in a manner similar to the manner of control of actuator1951 via the connections shown in FIG. 6.

The user programs controller 1016 via data inputs on a user interface toinstruct the hydraulic system 1700 to drive pins 1041, 1042 at anupstream velocity of travel that is reduced relative to a maximumvelocity that the hydraulic system can drive the pins 1041, 1042 totravel. As described below, such reduced pin withdrawal rate or velocityis executed until a position sensor such as 1951, 1952 detects that anactuator 1941, 1942 or an associated valve pin (or another component),has reached a certain position such as the end point of a restrictedflow path RP. A typical amount of time over which the pins are withdrawnat a reduced velocity is between about 0.01 and 0.10 second, the entireinjection cycle time typically being between about 0.3 seconds and about3 seconds, more typically between about 0.5 seconds and about 1.5seconds.

FIG. 6 shows position sensors 1950, 1951, 1952 for sensing the positionof their respective actuator cylinders (1940, 1941, 1942) and theirassociated valve pins (1040, 1041, 1042) and feeding such positioninformation to controller 1016 for monitoring purposes. As shown, fluidmaterial 1018 is injected from an injection machine into a manifoldrunner 1019 and further downstream into the bores 1044, 1046 of thelateral nozzles 1024, 1022 and ultimately downstream through the gates1032, 1034, 1036. When the pins 1041, 1042 are withdrawn upstream to aposition where the tip end of the pins 1041, 1042 are in a fullyupstream open FO position such as shown in FIG. 6D, the rate of flow offluid material through the gates 1034, 1036 is at a maximum. Howeverwhen the pins 1041, 1042 are initially withdrawn beginning from theclosed gate position, FIG. 6A, to intermediate upstream positions, FIGS.6B, 6C, a gap 1154, 1156 that restricts the velocity of fluid materialflow is formed between the outer surfaces 1155 of the tip end of thepins 1044, 1046 and the inner surfaces 1254, of the gate areas of thenozzles 1024, 1020. The restricted flow gap 1154, 1156 remains smallenough to restrict and reduce the rate of flow of fluid material Mthrough gates 1034, 1036 to a rate that is less than maximum flowvelocity over a travel distance RP of the tip end of the pins 1041, 1042going from closed to upstream as shown in FIGS. 6, 6B, 6C, 6E.

The trace or visible lines that appear in the body of a part that isultimately formed within the cavity of the mold on cooling above can bereduced or eliminated by reducing or controlling the velocity of the pin1041, 1042 opening or upstream withdrawal from the gate closed positionto a selected intermediate upstream gate open position that ispreferably 75% or more of the length of RP. RP can be about 1-8 mm inlength and more typically about 2-6 mm and even more typically 2-4 mm inlength. As shown in FIG. 7 in such an embodiment, a control system orcontroller 1016 is programmed to control the sequence and/or the ratesof valve pin 1040, 1041, 1042 opening and/or closing.

The velocity of withdrawal of the valve pins 1041, 1042 is determined byregulation of the flow of hydraulic drive fluid that is pumped from asupply 1014 to the actuators 1941, 1942 through a flow restrictor valve1600, FIGS. 6-7. When the flow restrictor valve 1600 is completely open,namely 100% open, allowing maximum flow of the pressurized hydraulicfluid to the actuator cylinders, the valve pins 1041, 1042 are driven ata maximum upstream travel velocity. The degree of openness of the flowrestrictor valve is adjusted in response to sensing of position of asuitable component such as an actuator 1941, 1942 or associated valvepin to less than 100% open. Adjustment of the flow restrictor valve 1600to less than 100% open thus reduces the rate and volume flow ofpressurized hydraulic fluid to the actuator cylinders thus in turnreducing the velocity of upstream travel of the pins 1041, 1042 for theselected period of time. At the end of the travel or length of path RP,a position sensor signals the controller 1016, the controller 1016determines that the end has been reached and the valve 1600 is opened toa higher velocity, typically to its 100% open position to allow theactuator pistons and the valve pins 1041, 1042 to be driven at maximumupstream velocity in order to reduce the cycle time of the injectioncycle.

The valve 1600 typically comprises a restrictor valve that iscontrollably positionable anywhere between completely closed (0% open)and completely open (100% open). Adjustment of the position of therestrictor valve 1600 is typically accomplished via a source ofelectrical power that controllably drives an electromechanical mechanismthat causes the valve to rotate such as a rotating spool that reacts toa magnetic or electromagnetic field created by the electrical signaloutput of the controller 1016, namely an output of electrical energy,electrical power, voltage, current or amperage the degree or amount ofwhich can be readily and controllably varied by conventional electricaloutput devices. The electro-mechanism is controllably drivable to causethe valve 1600 to open or close to a degree of openness that isproportional to the amount or degree of electrical energy that is inputto drive the electro-mechanism. The velocity of upstream withdrawaltravel of the pins 1041, 1042 are in turn proportional to the degree ofopenness of the valve 1600.

FIGS. 8A-8D show various examples of position sensors, the mounting andoperation of which are described in U.S. Patent Publication No.2009/0061034, the disclosure of which is incorporated herein byreference. As shown the position sensor 800 of FIGS. 8A and 8B forexample can track and signal the position of the piston of an actuatorpiston 823 continuously along its entire path of travel from which dataa pin velocity can be continuously calculated over the length of RP viaa spring loaded follower 802 that is in constant engagement with flange804 during the course of travel of piston 823. Mechanism 800 constantlysends signals to controller 1016 in real time to report the position ofpin 1041 and its associated actuator. FIGS. 8C, 8D show alternativeembodiments using position switches that detect position at specificindividual positions of the actuator and its associated valve pin 1041.The FIG. 8C embodiment uses a single trip position switch 830 a withtrip mechanism 833 that physically engages with the piston surface 823 awhen the piston 823 reaches the position of the trip mechanism 833. TheFIG. 8D embodiment shows the use of two separate position switches 830a, 830 aa having sequentially spaced trips 833 aa and 833 aaa thatreport the difference in time or distance between each trip engagingsurface 823 a of the piston, the data from which can be used bycontroller 1016 to calculate velocity of the actuator based on the timeof travel of the actuator from tripping one switch 830 a and thentripping the next 830 aa. In each embodiment the position switch cansignal the controller 1016 when the valve pin 1041, 1042 has travelledto one or more selected intermediate upstream gate open positionsbetween GC (gate closed) and RP so that the velocity of the pin can beadjusted to the selected or predetermined velocities determined by theuser. As can be readily imagined other position sensor mechanisms can beused such as optical sensors, sensors that mechanically orelectronically detect the movement of the valve pin or actuator or themovement of another component of the apparatus that corresponds tomovement of the actuator or valve pin.

In alternative embodiments the controller can include a processor andinstructions that receive the pin position information and signals fromthe position sensor and calculate the real time velocity of the pin fromthe pin position data in real time at one or more times or positionsover the course of the pin travel through the RP path length and/orbeyond. Typically such calculations of velocity are continuousthroughout the cycle. In such an embodiment, the calculated pin velocityis constantly compared to a predetermined target profile of pinvelocities and the velocity of the pin is adjusted in real time by thecontroller 1016 to conform to the profile. In this embodiment, as in theprevious described embodiment, the pin is moved continuously upstream atall times between the gate closed position and all positions upstream ofthe gate closed position. Such control systems are described in greaterdetail in for example U.S. Patent Publication No. 2009/0061034, thedisclosure of which is incorporated herein by reference.

As discussed above, control over the velocity of pin movement in anembodiment where the pin is driven by a hydraulic or pneumatic actuatoris typically accomplished by controlling the degree of openness of thefluid restriction valve 1600, control over velocity and drive rate orposition of valve 1600 being the same functions in terms of theinstructions, processor design or computer software that carries outinstructing and implementing the velocity or drive rate adjustment tothe valve pin or actuator. Where the position sensing system senses theposition of the pin or other component multiple times throughout thecourse of the pin or other component movement, and real time velocitycan be calculated by the controller 1016, a program or instructions canbe alternatively used to receive a velocity data input by the user tothe controller 1016 as the variable to be stored and processed insteadof a predetermined voltage or current input Where an actuator thatcomprises an electric motor is used as the drive mechanism for movingthe valve pin 1041, 1042 instead of a fluid driven actuator, thecontroller 1016 can similarly be programmed to receive and processvelocity data input as a variable for controlling the velocity or rateof drive of the electric actuator.

User Interface and Target Profiles

FIG. 9 shows time versus pressure graphs (1235, 1237, 1239, 1241) of thepressure detected by four pressure transducers associated with fournozzles mounted in a manifold block. The four nozzles are substantiallysimilar to the nozzles shown in FIG. 6 and include pressure transducerscoupled to the controller 1016.

The graphs of FIGS. 9A-9D are generated on a user interface (e.g., 21,71 of FIG. 1), so that a user can observe the tracking of the actualpressure versus the target pressure during the injection cycle in realtime, or after the cycle is complete. The four different graphs of FIG.9 show four independent target pressure profiles (“desired”) emulated bythe four individual nozzles. Different target profiles are desirable touniformly fill different sized individual cavities associated with eachnozzle, or to uniformly fill different sized sections of a singlecavity. Graphs such as these can be generated with respect to any of theprevious embodiments described herein.

The valve pin associated with graph 1235 is opened sequentially at 0.5seconds after the valves associated with the other three graphs (1237,1239 and 1241) were opened at 0.00 seconds. At approximately 6.25seconds, at the end of the injection cycle, all four valve pins are backin the closed position. During injection (for example, 0.00 to 1.0seconds in FIG. 9B) and pack (for example, 1.0 to 6.25 seconds in FIG.9B) portions of the graphs, each valve pin is controlled to a pluralityof positions to alter the pressure sensed by the pressure transducerassociated therewith to track the target pressure.

Through the user interface, target profiles can be designed, and changescan be made to any of the target profiles using standard (e.g.,windows-based) editing techniques. The profiles are then used bycontroller 1016 to control the position of the valve pin. For example,FIG. 10 shows an example of a profile creation and editing screen 1300generated on a user interface.

Screen 1300 is generated by a windows-based application performed on theuser interface, e.g., any of the user interfaces 21 shown in FIG. 1.Alternatively, this screen display could be generated on an interfaceassociated with the controller (e.g., display 71 associated withcontroller 8 in FIG. 1). Interactive screen 1300 provides a user withthe ability to create a new target profile or edit an existing targetprofile for any given nozzle and cavity associated therewith.

A profile 1310 includes (x, y) data pairs, corresponding to time values1320 and pressure values 1330 which represent the desired pressuresensed by the pressure transducer for the particular nozzle beingprofiled. The screen shown in FIG. 10 is shown in a “basic” mode inwhich a limited group of parameters are entered to generate a profile.For example, in the foregoing embodiment, the “basic” mode permits auser to input start time displayed at 1340, maximum fill pressuredisplayed at 1350 (also known as injection pressure), the start of packtime displayed at 1360, the pack pressure displayed at 1370, and thetotal cycle time displayed at 1380.

The screen also allows the user to select the particular valve pin theyare controlling displayed at 1390, and name the part being moldeddisplayed at 1400. Each of these parameters can be adjustedindependently using standard windows-based editing techniques such asusing a cursor to actuate up/down arrows 1410, or by simply typing invalues on a keyboard. As these parameters are entered and modified, theprofile will be displayed on a graph 1420 according to the parametersselected at that time.

By clicking on a pull-down menu arrow 1391, the user can selectdifferent nozzle valves in order to create, view or edit a profile forthe selected nozzle valve and cavity associated therewith. Also, a partname 1400 can be entered and displayed for each selected nozzle valve.

The newly edited profile can be saved in computer memory individually,or saved as a group of profiles for a group of nozzles that inject intoa particular single or multi-cavity mold. The term “recipe” is used todescribe one or more of profiles for a particular mold and the name ofthe particular recipe is displayed at 1430 on the screen icon.

To create a new profile or edit an existing profile, first the userselects a particular nozzle valve of the group of valves for theparticular recipe group being profiled. The valve selection is displayedat 1390. The user inputs an alpha/numeric name to be associated with theprofile being created, for family tool molds this may be called a partname displayed at 1400. The user then inputs a time displayed at 1340 tospecify when injection starts. A delay can be with particular valve pinsto sequence the opening of the valve pins and the injection of meltmaterial into different gates of a mold.

The user then inputs the fill (injection) pressure displayed at 1350. Inthe basic mode, the ramp from zero pressure to max fill pressure is afixed time, for example, 0.3 seconds. The user next inputs the startpack time to indicate when the pack phase of the injection cycle starts.The ramp from the filling phase to the packing phase is also fixed timein the basic mode, for example, 0.3 seconds.

The final parameter is the cycle time which is displayed at 1380 inwhich the user specifies when the pack phase (and the injection cycle)ends. The ramp from the pack phase to zero pressure may be instantaneouswhen a valve pin is used to close the gate, or slower in a thermal gatedue to the residual pressure in the cavity which will decay to zeropressure once the part solidifies in the mold cavity.

User input buttons 1415 through 1455 are used to save and load targetprofiles. Button 1415 permits the user to close the screen. When thisbutton is clicked, the current group of profiles will take effect forthe recipe being profiled. Cancel button 1425 is used to ignore currentprofile changes and revert back to the original profiles and close thescreen. Read Trace button 1435 is used to load an existing and savedtarget profile from memory. The profiles can be stored in memorycontained in one or more of the operator interface 21, the main MCU 9,and the recipe storage MCU 16. Save trace button 1440 is used to savethe current profile. Read group button 1445 is used to load an existingrecipe group. Save group button 1450 is used to save the current groupof target profiles for a group of nozzle valve pins. The process tuningbutton 1455 allows the user to change the settings (for example, thegains) for a particular nozzle valve in a control zone. Also displayedis a pressure range 1465 for the injection molding application.

While specific embodiments of the present invention have been shown anddescribed, it will be apparent that many modifications can be madethereto without departing from the scope of the invention. For example,in one embodiment the controller is mounted on a hydraulic power unit.In one embodiment, the flow control MCU receives, displays and/orrecords a signal from an electronic mold counting sensor for correlatingdetected pin motion data to the recipe data for a given molding cycle.In one embodiment, the system includes a plurality of flow control MCU'seach controlling a corresponding one of a plurality of pins. In oneembodiment, the flow control MCU transmits signals to an electric motorfor controlling one or more of pin position and rate of pin movement. Inone embodiment, both the recipe MCU and the flow control MCU are mountedto the mold. In one embodiment, the controller is contained in aphysical box which is mounted to the injection machine and/or placednear the injection machine. In one embodiment, the controller associates(compares) the recipe data to data collected during one injection cycle.In one embodiment, each valve pin has its own profile per injectioncycle, and the recipe is a collection of such profiles for a pluralityof pins.

In one embodiment, a mold having no recipe or a non-approved (notcurrent or previously tested) recipe stored in the recipe storage MCU,is mounted to the machine. An operator can then create a recipe bytesting different inputs to the controller, e.g., adjusting the rate ofspeed and/or position of one or more pins. When the user is satisfiedwith the parts being produced in the mold or with data and/or signalsreceived from the mold (e.g., temperature and/or pressure), the operatorthen stores a copy of the newly created recipe by transmitting (director indirectly) the new recipe for storage on the recipe storage MCU. Themain MCU of the controller stores a local copy of the new recipe, andruns the recipe (executes instructions implementing the recipe) for themold. Then later, if this first mold is removed and a new mold ismounted to the machine, where the new mold has a proper recipe alreadystored on the new mold MCU, the controller can then immediately run thenew recipe for the new mold on the machine. If not, the operator canagain create a new recipe for the new mold, as previously described.

The recipe data typically comprises a profile of values of a conditionof the injected polymer material or a condition or position of aselected component of the injection molding apparatus that is specifiedto occur at each point in time over the course or duration of aninjection cycle when a part is produced in the mold cavity. Thus aprofile defines a set of conditions, events or positions to which theinjection material or the component of the apparatus is adjusted toattain over the course of a particular injection cycle. Typicalinjection material conditions that can be specified and controlled arepressure of the injection material at selected positions within a flowchannel of the manifold, within an injection nozzle or within the moldcavity. Typical conditions or positions of components of the apparatusthat can be controlled and comprise a profile are the position of thevalve pin, the position of the screw of the barrel of the injectionmolding machine and position of an actuator piston. Such profiles andrecipes are disclosed in detail in for example U.S. Pat. Nos. 6,464,909and 8,016,581 and 7,597,828, the disclosures of which are incorporatedby reference as if fully set forth herein.

Various other embodiments will be apparent to the skilled person.Accordingly, the invention is not limited by the foregoing embodiments.

The invention claimed is:
 1. A flow control system for implementing aninjection molding process in which one or more nozzles, during aninjection cycle, feed fluid material(s) into a cavity of a mold, eachnozzle having an associated valve pin, driven by an associated actuator,for opening and closing a respective gate into the cavity, and aposition sensor is associated with each valve pin for monitoring aplurality of actual pin positions with respect to the gate andgenerating a sensor output signal indicative of the plurality of actualpin positions as the valve pin moves between gate closed and gate openpositions, the flow control system comprising: a junction box coupled toa recipe storage on the mold and providing a wireless communicationinterface for transmitting and receiving wireless communications witheach of: a controller that controls movement of each valve pin over thecourse of the injection cycle in accordance with a set of processparameters, the controller being in wireless communication with thejunction box; a mobile user interface, in wireless communication withthe junction box, configured to receive input from a human operator inthe form of process parameters and commands relating to the injectionmolding process for wireless transmission to at least one of thejunction box and the controller; the flow control system beingconfigured to receive and process the sensor output signal from anassociated position sensor to determine, from the plurality of actualpin positions, one or more actual process parameters; and a user displaybeing configured to receive and display the plurality of actual pinpositions and/or the one or more actual process parameters by which ahuman operator can track the molding process in real time during theinjection cycle; wherein one or more of the junction box and thecontroller are configured to process the sensor output signal togenerate a control signal to control the pin position; and the mobileuser interface is configured to receive operator input for adjusting thecontrol signal to control the pin position.
 2. The system of claim 1,wherein the user display is provided on the mobile user interface. 3.The system of claim 2, wherein the wireless communication interfacecomprises a radio frequency (RF) transceiver configured forbi-directional communication with the mobile user interface.
 4. Thesystem of claim 3, wherein the RF transceiver consists of one or more ofa Wi-Fi antenna, a Bluetooth antenna, and an NFC (Near FieldCommunication) antenna.
 5. The system of claim 3, wherein the flowcontrol system is configured to use the RF transceiver to transmit, tothe mobile user interface, data indicative of the plurality of actualpin positions and/or the one or more actual process parameters.
 6. Thesystem of claim 3, wherein the flow control system is configured to usethe RF transceiver to transmit, to the mobile user interface, datacomprising one or more of: pin position status; pin opening and/or pinclosing times; pin opening and/or pin closing velocities; and continuousactual pin position data for a graphical display of the plurality ofactual pin positions versus time.
 7. The system of claim 1, wherein themobile user interface includes operator commands for one or more modesof operation including calibration, continuous monitoring of the actualpin position, and discrete determination of the actual pin position asopened or closed.
 8. The system of claim 7, wherein calibration istriggered by an operator input to the mobile user interface from thehuman operator.
 9. The system of claim 8, wherein in response to theoperator input the mobile user interface is configured to generate acalibration command and transmit the calibration command to one or moreof the junction box and the controller.
 10. The system of claim 9,wherein one or more of the junction box and the controller areconfigured to calibrate the position sensor associated with each valvepin in response to the calibration command being received by one or moreof the junction box and the controller.
 11. The system of claim 10,wherein calibration data for each calibrated position sensor is storedlocally in a memory of the junction box.
 12. The system of claim 2,wherein the mobile user interface comprises a mobile telephone,smartphone, or tablet.
 13. The system of claim 2, wherein the displaycomprises a display for viewing one or more of: a status indicator ofthe actual pin position; a graph of the actual pin position versus time;and the actual pin opening time and pin opening velocity.
 14. The systemof claim 1, wherein the position sensor comprises a Hall Effect sensoror a Hall Effect circuit including a Hall Effect sensor and one or moreof a power regulator, signal amplifier, current converter, and signaldriver.
 15. The system of claim 14, wherein: the Hall Effect sensorgenerates a voltage output signal; the voltage output signal isamplified and converted to a current output signal by the Hall Effectcircuit; and the current output signal is transmitted as the sensoroutput signal from an output port of the Hall Effect circuit to an inputport of the junction box or the controller.
 16. A method of monitoringvalve pin positioning in an injection molding system having a cavitywith one or more gates and one or more actuator-driven valve pins eachassociated with a respective gate for opening and closing the respectivegate, the method comprising, for each of the respective actuator-drivenvalve pins: controlling, via a flow control system that implements a setof process parameters for controlling a molding process in the cavity,an actuator that drives an associated valve pin with respect to anassociated gate of the cavity along a travel path including a pluralityof actual pin positions between gate open and gate closed positions;detecting, via a position sensor that monitors movement of an associatedvalve pin while the valve pin moves along the travel path between thegate closed position, closing the associated gate to the cavity, to thegate open position, allowing fluid material to flow through the gate andinto the cavity, and transmitting as a position sensor output signal tothe flow control system a detected actual movement of the valve pinalong the travel path upon opening of the gate indicative of an actualpin opening velocity and an actual pin opening time; receiving theposition sensor output signal and generating display data indicative ofactual process parameters including the actual pin opening time and theactual pin opening velocity; and displaying, via a user display, thedisplay data enabling a human operator to track the actual processparameters in real time during the injection cycle including the actualpin opening time and the actual pin opening velocity; wherein the flowcontrol system includes a junction box coupled to a recipe storage onthe mold and providing a wireless communication interface fortransmitting and receiving wireless communications with each of thecontroller and a mobile user interface, and the method furthercomprising: receiving, by the mobile user interface, input from a humanoperator in the form of process parameters or commands relating to theinjection molding process for wireless transmission to at least one ofthe junction box and the controller; wherein the controlling stepincludes using the position sensor output signal to generate a controlsignal to control the pin position; and receiving, at the mobile userinterface, operator input for adjusting the control signal to controlthe pin position.
 17. The method of claim 16, wherein the user displayis provided on the mobile user interface.
 18. The method of claim 17,wherein the method comprises using a radio frequency (RF) transceiver asthe wireless communication interface to perform bi-directionalcommunication with the mobile user interface.
 19. The method of claim18, wherein the RF transceiver comprises one or more of a Wi-Fi antenna,a Bluetooth antenna, and an NFC (Near Field Communication) antenna. 20.The method of claim 19, wherein the displaying step includes generatingas the display data continuous actual pin position data for a graphicaldisplay of the plurality of actual pin positions versus time andtransmitting the display data to the mobile user interface via the RFtransceiver.
 21. The method of claim 16, wherein the method is adaptedfor use in calibration of the injection molding system, whereincalibration is triggered by an input to the mobile user interface fromthe human operator.
 22. The method of claim 21, wherein the mobile userinterface is configured to generate a calibration command and transmitthe calibration command to one or more of the junction box and thecontroller via the RF transceiver.
 23. The method of claim 22, whereinone or more of the junction box and the controller calibrate theposition sensors associated with each valve pin in response to thecalibration command being received by the RF transceiver.
 24. The methodof claim 23, further comprising storing calibration data for eachcalibrated position sensor locally in a memory of the junction box. 25.The method of claim 16, wherein the displaying step comprises displayinga status indicator of the actual pin position for one or more of thepins of the injection molding system.
 26. The method of claim 16,wherein the displaying step comprises displaying data comprising one ormore of: pin position status; pin opening and/or pin closing time; pinopening and/or pin closing velocities; and continuous actual pinposition data for a graphical display of the plurality of actual pinpositions versus time.
 27. The method of claim 26, wherein the positionsensor comprises one or more Hall Effect sensors for an associated valvepin.
 28. A non-transitory computer readable medium storing a flowcontrol application for monitoring flow control during an injectionmolding process in which one or more nozzles, during an injection cycle,feed fluid material(s) into a cavity of a mold, each nozzle having anassociated valve pin, driven by an associated actuator, for opening andclosing a respective gate into the cavity, and a controller controlsmovement of the valve pins over the course of the injection cycle inaccordance with a set of process parameters, the flow controlapplication providing an interactive screen and a user display on amobile user interface and a wireless communication channel with at leastone of a junction box coupled to a recipe storage on the mold and acontroller for monitoring flow control during the injection cycle,wherein the interactive screen enables an operator to input processparameters or commands, via the wireless communication channel, for oneor more of the controller and the junction box for performing a methodincluding steps of: monitoring, via a position sensor associated witheach valve pin, a plurality of actual pin positions with respect to thegate and generating a sensor output signal indicative of the pluralityof actual pin positions as the valve pin moves between gate closed andgate open positions; processing, via the controller, the sensor outputsignal from the associated position sensor to determine, from theplurality of actual pin positions, one or more actual processparameters; and displaying, on the user display, the plurality of actualpin positions and/or the one or more actual process parameters by whicha human operator can track the molding process in real time during theinjection cycle; and using the position sensor output signal to generatea control signal to control the pin position; and receiving, at themobile user interface, operator input for adjusting the control signalto control the pin position.
 29. The flow control application forimplementing the method of claim 28, wherein the wireless communicationchannel comprises a radio frequency (RF) transceiver on the junction boxconfigured for bi-directional communication with the mobile userinterface.
 30. The flow control application for implementing the methodof claim 29, wherein the RF transceiver comprises one or more of a Wi-Fiantenna, a Bluetooth antenna, and an NFC (Near Field Communication)antenna.
 31. The flow control application for implementing the method ofclaim 29, wherein the junction box is further configured to use the RFtransceiver to transmit, to the mobile user interface, data indicativeof the plurality of actual pin positions and the one or more actualprocess parameters.